Benchmark 1500 - 2000 Boilers
CHAPTER 7 – MAINTENANCE
Page 92 of 182 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0097_0E
10/01/2015 Ph.: 800-526-0288 GF-142
7.6 BURNER ASSEMBLY INSPECTION
The burner assembly is located at the top of the unit's heat exchanger. The burner assembly
may be hot. Therefore, allow the unit to cool sufficiently before removing the burner assembly.
The following parts will be required for reassembly after burner inspection:
Part No. Description
Burner Release Gasket (1 each)
Burner Lower Release Gasket (1 each)
Flame Detector Gasket (1 each)
To inspect or replace the burner assembly, proceed as follows:
Burner Assembly Inspection and Maintenance Procedures
1. Set the ON/OFF switch on the control panel to the OFF position. Disconnect AC power
from the unit and turn off the gas supply.
2. Remove the top shroud from the unit by grasping the top handle and lifting straight up.
This will disengage the shroud from the four (4) pins in the side panels.
3. Disconnect the lead wire from the flame detector installed on the burner plate. See Figure
7-2.
4. Remove the two (2) screws securing the flame detector to the plate. The flame detector is
secured to the burner plate with one (1) #10-32 screw and one (1) #8-32 screw.
5. Remove the flame detector and gasket from the burner plate.
6. Disconnect the cable from the igniter-injector.
7. Using a 7/16” open-end wrench, disconnect the compression nut securing the gas injector
tube of the igniter-injector to the elbow of the staged ignition assembly (see Figure 7-2).
Disconnect the staged ignition assembly from the igniter-injector.
8. Next, loosen and remove the igniter-injector from the burner plate using a 1" open-end
wrench.
9. Loosen and remove the four 5/16x1-3/4” bolts, washers, and nuts from the blower plenum
where it is attached to the blower (see Figure 7-4a & 7-4b).
10. You must either rig a support for the blower to hold it in place or remove the blower from
the unit and set it aside for later reassembly.
11. Remove the eight (8) 3/8-16 nuts, using a 9/16” wrench, attaching the blower plenum to
the burner (see Figure 7-4a & 7-4b).
12. Remove the blower plenum from between the blower and the burner and set it aside for
later reassembly. The O
2
sensor and flame observation port remain assembled to the
plenum flange.
13. Remove the burner by pulling straight up.
14. Remove and replace the burner gasket(s) (see Figure 7-5).
NOTE
The burner assembly weighs approximately 65 lbs (29.5 kg).
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